GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Oldsmobile 🢒 1999 🢒 Shelby Series 1 🢒 Engine 🢒 Engine Controls - 4.0L 🢒 Fuel Sender Assembly Replacement

Removal Procedure

    Object Number: 626278 Size: SH

    Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  3. Drain the fuel tank. Refer to Fuel Tank Draining .
  4. Remove the fuel tank (2). Refer to Fuel System.

    5. Object Number: 626241 Size: SH
  5. Remove the fuel tank pressure sensor (3).
  6. Remove the fuel sender assembly attaching screws, the fuel sender assembly (2), and the gasket (4). Discard the gasket (4).
  7. Clean the gasket sealing surfaces.
  8. Inspect the fuel feed hose, the fuel return hose, and the evaporative emission (EVAP) hose for cuts, nicks, swelling, or distortion. Replace the hoses if necessary.

Installation Procedure

    Object Number: 626241 Size: SH
  1. Position the new gasket on the fuel tank.
  2. Carefully fold the strainer to allow it to fit through the opening in the fuel tank. Make sure the strainer unfolds once it is placed in the tank.
  3. Install the fuel sender assembly (2) into the fuel tank.

    4. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4. Install the fuel sender assembly attaching screws (7).

    5. Tighten
    Tighten the fuel sender assembly attaching screws alternately and evenly to 4.5 N·m (40 lb in).

  5. Install the fuel tank pressure sensor (3).

    6. Object Number: 626278 Size: SH
  6. Install the fuel tank. Refer to the Fuel System.
  7. Install the fuel filler cap.
  8. Connect the negative battery cable.
  9. Inspect for leaks.
    10. 9.1. Turn the ignition switch ON for 2 seconds.
    9.2. Turn the ignition switch OFF for 10 seconds.
    9.3. Turn the ignition switch ON.
    9.4. Check for fuel leaks.